Methods to make glass compositions and fibers made therefrom

Patent metadata

Field	Value
Publication number	US-10377663-B2
Application number	US-201715408946-A
Country	US
Kind code	B2
Filing date	Jan 18, 2017
Priority date	Aug 3, 2009
Publication date	Aug 13, 2019
Grant date	Aug 13, 2019

Abstract

Embodiments of the present invention provides fiberizable glass compositions formed from batch compositions comprising amounts of one or more glassy minerals, including perlite and/or pumice.

First claim

That which is claimed:

1. A method of producing a glass fiber, the method comprising:
(a) providing a batch composition comprising:
at least 10 weight percent of a glassy mineral and at least 5 weight percent of a sodium source, the glassy mineral comprising a combination of SiO 2 and Al 2 O 3 in an amount of at least 80 weight percent;
at least 10 weight percent of an additional source of silicon, aluminum, or both silicon and aluminum; and
a sufficient amount of an alkali metal oxide (R 2 O) component comprising K 2 O, such that the glass fiber produced comprises 8.5 to 18 weight percent of R 2 O and further comprises from 0.5 to 4 weight percent K 2 O;
(b) heating the batch composition to form a molten glass composition; and
(c) extruding the molten glass composition through a bushing to form a glass fiber.

2. The method of claim 1 , wherein the batch composition is heated to a fiber forming temperature ranging from about 1120° C. to about 1300° C.

3. The method of claim 1 , wherein the batch composition is heated to a temperature ranging from about 1400° C. to about 1450° C.

4. The method of claim 1 , wherein the batch composition is heated to a fiber forming temperature which differs from a liquidus temperature of a glass composition from about 45° C. to about 165° C.

5. The method of claim 1 , wherein the batch composition comprises at least 25 weight percent of the glassy mineral.

6. The method of claim 1 , wherein the batch composition comprises at least 40 weight percent of the glassy mineral.

7. The method of claim 1 , wherein the glassy mineral comprises perlite, pumice or mixtures thereof.

8. The method of claim 1 , wherein the batch composition comprises at least 10 weight percent of the sodium source.

9. The method of claim 1 , wherein the batch composition comprises at least 10 weight percent of an additional source of silicon.

10. The method of claim 9 , wherein the source of silicon comprises 34-56 weight percent silica.

11. The method of claim 1 , wherein the batch composition comprises at least 10 weight percent of an additional source of aluminum.

12. The method of claim 11 , wherein the source of aluminum comprises corundum.

13. The method of claim 1 , wherein the batch composition comprises at least 10 weight percent of an additional source of both silicon and aluminum.

14. The method of claim 13 , wherein the source of both silicon and aluminum comprises at least one of kaolinite, dickite, halloysite, nacrite, montmorillonite, or alkali metal aluminosilicates.

15. The method of claim 14 , wherein the source of both silicon and aluminum comprises up to 19 weight percent kaolinite.

16. The method of claim 1 , further comprising at least one additional mineral comprising limestone, dolomite, or mixtures thereof.

17. The method of claim 16 , wherein the additional mineral comprises up to 55 weight percent dolomite.

18. The method of claim 16 , wherein the additional mineral comprises up to 17 weight percent limestone.

19. The method of claim 1 , wherein the glass fiber comprises:
53-64 weight percent SiO 2 ;
8-12 weight percent Al 2 O 3 ; and
a metal oxide (RO) component comprising MgO, CaO, SrO, BaO, or ZnO or mixtures thereof,

wherein the metal oxide component is present in an amount to provide a mass ratio of R 2 O/RO ranging from about 0.28 to about 1.5.

Assignees

• Ppg Ind Ohio Inc

Inventors

• Li Hong
• Watson James C

Classifications

• C03B37/02

  by drawing or extruding, {e.g. direct drawing of molten glass from nozzles; Cooling fins therefor (C03B37/04 takes precedence; sizing of the fibres C03C25/00)} · CPC title

• C03C2204/00

  Glasses, glazes or enamels with special properties · CPC title

• C03C4/20

  for chemical resistant glass · CPC title

• C03C3/087

  containing calcium oxide, e.g. common sheet or container glass · CPC title

• C03C13/06 Primary

  Mineral fibres, e.g. slag wool, mineral wool, rock wool · CPC title